Hosiery



Oct. 19, 1965 M. M. FREDERICK 3,212,299

HOSIERY Filed June 21, 1962 4 Sheets-Sheet 2 In Hu DI" E" FIGB.

Oct. 19, 1965 M. M. FREDERICK 3,212,299

HOSIERY Filed June 21, 1962 4 sheets-sneer. s

Oct. 19, 1965 M. M. FREDERICK 3,212,299

HOSIERY Filed June 2l, 1962 4 Sheets-Sheet 4 United States Patent 3,212,299 HSIERY Mahlon M. Frederick, Souderton, Pa., assignor, by mesne assignments, `to Vac Hosiery Corporation, Charlotte, N.C., a corporation of North Carolina Filed .inne 21, 1962, Ser. No. 204,240 4 Claims. (Cl. 66-178) This invention relates to hosiery and, more particularly, to Womens seamless nylon hosiery knitted on a circular knitting machine.

Seamless nylon hosiery is conventionally knitted on a circular knitting machine. In such a machine a thread or yarn is knitted by a plurality of needles arrangedl circumferentially in a cylinder into a :series of interconnected courses and wales. The courses extend circumferentially of the finished hosiery and the wales extend vertically or longitudinally thereof.

In the usual plain stitch seamless stocking, a course is formed by each knitting revolution of the knitting cylinder. As the knitting cylinder rotates, each needle knits a plain stitch and adds the stitch to the stitch knitted in the preceding course to form the vertically extending Wale. Thus, when the hosiery is completed, each vertically extending Wale is for-med by a chain of interlooped stitches extending vertically or longitudinally of the hosiery. The plain stitches in such hosiery are relatively small and `substantially uniform in size. When knitted with relatively line thread, for example ten denier or finer, and on a machine having 400 or more needles in the knitting cylinder, such hosiery are uniform and sheer.

While plain knitted nylon hosiery have been widely accepted and are widely used, such hosiery are easily damaged. Each Wale is a chain of interlooped stitches held in the chain by the adjoining stitches. When the yarn in one stitch is broken, such stitch is released, the chain is broken and the adjoining stitches in the Wale are progressively released. A run or ladder is thereby formed. Such a run or ladder can easily be started by snagging and breaking a thread particularly where the thread is relatively fine.

Numerous attempts heretofore have been made to prevent seamless hosiery from running. In some instances, the hosiery have been made run-resistant and, in others, attempts have been made to make the hosiery run-proof. Such attempts, generally, have entailed knitting multiple threads into a single fabric, either by double knitting a single thread or by concurrently knitting two or more threads. The pattern knitted into such fabric has also been altered. This results in a change in the appearance of the hosiery. Instead of the uniform, sheer hosiery associated ywith plain stitches, a coarse, net-like or mesh hosiery is produced. Appearance is, therefore, sacrificed. In addition, many such hosiery lack elasticity, a property of considerable importance in hosiery.

As has been noted above, the vertically extending Wales are formed by a chain of interlooped stitches extending vertically of the hosiery and a ladder or run occurs when the yarn in one stitch is broken and adjoining stitches are progressively released. A run or ladder, therefore, is a vertical failure in the hosiery. Run-proof hosiery heretofore proposed do not, generally, reinforce the hosiery vertically or hold the stitch in the Wale. Rather, each Wale is connected at spaced intervals to adjoining wales so that, when a stitch in the Wale is broken, the Wale is held or reinforced horizontally. Although running or laddering occurs lengthwise of the Wale and longitudinal of the hosiery, when the Wale is connected to adjacent wales, the hosiery is reinforced transversely and not in the direction of failure. In other words, once a stitch in a Wale is broken, such Wale is eliminated as a structural part of the hosiery. When such an event occurs, the interconnection With the adjoining wales is substituted for the structural function of the disabled Wale. Although such substitution may be effective to temporarily prevent running or laddering, should the transverse connection between the wales subsequently fail, a run will result.

Under the present invention, run-proof knitted seamless hosiery are provided in which the wales are reinforced vertically as well as horizontally. Each stitch in each Wale is reinforced by the stitches in the adjacent wales and by the .stitches in its own wale. When a stitch in the Wale is broken, the broken stitch is held or reinforced by the stitches in the wales on the opposite sides of the broken stitch. In addition, the stitches in the Wale above and below the broken stitch are held. Thus, even though a wale `may contain a broken stitch, such wale continues as a structural part of the hosiery. In the hosiery of the instant invention the wales are, therefore, reinforced vertically as well as horizontally. Should either the vertical or horizontal reinforcement fail, the wale will continue to be held and a run will not result.

It is an object of the present invention to provide a new and improved run-proof hosiery.

A further object of the invention is to provide such hosiery having a uniform pattern, such as in plain knit hosiery, and which are sheer and do not have a mesh or net-like appearance.

Still a further object of the invention is to provide such hosiery in Iwhich the individual stitches in each Wale are reinforced both vertically and horizontally.

A still further object of the invention is to provide multi-fabric hosiery in which the stitches of one fabric are reinforced and held by the stitches of the other fabric.

Another object of the invention is to provide a runproof hosiery which can be knitted on existing circular knitting machinery currently in use for producing conventional seamless hosiery.

These and other objects will be apparent and more fully understood from the following description and the attached -drawings in which:

FIG. 1 is a diagram of the knitted pattern of the forming and `shaping fabric of the instant invention, the knitted stitches in the diagram being enlarged and expanded for purposes of illustration;

FIG. 2 is a diagram similar to FIG. l but showing the knitted pattern `of the overlaying and filling fabric;

FIG. 3 is a diagram similar to FIGS. 1 and 2 but showing the two fabrics when knitted together into the composite fabric of the instant invention;

FIG. 3A is an enlarged diagram of the portion of the composite fabric designated 3A in FIG. 3;

FIG. 3B is an enlarged diagram of the portion of the composite fabric designated 3B in FIG. 3;

FIG. 4 is a photomicrograph of a portion of the forming and shaping fabric diagramed in FIG. l, as actually knitted, the photomicrograph being at a magnification one hundred times the size of the original fabric or at a linear magnitfication of ten to one;

FIG. 5 is a photomicrograph similar to FIG. 4 but showing the overlaying and filling fabric diagramed in FIG. 2; and

FIG. 6 is a pliotomicrograph similar to FIGS. 4 and but showing the two fabrics when knitted into the corn-` posite fabric of the instant invention.

Under the present invention run-proof knitted seamless hosiery are provided by concurrently knitting a plurality of yarns into superimposed, interknitted, overlaying fabrics in which at least one of the fabrics forms and shapes the hosiery and the remainder of the fabrics is joined to and reinforces the stitches of the forming and shaping fabric. As will be explained in more detail hereinafter, each of the wales in the forming and shaping fabric is interconnected with the adjoining Wales in such fabric so that, When the thread or yarn in a stitch of one Wale is broken, such Wale is held by the adjoining wales. In addition, the stitches of the forming and shaping fabric are interknitted with the stitches of the overlaying and superimposed fabric. Thus, the stitches in the composite fabric contain at least two yarns or threads, one from the forming and shaping fabric and the other from the superimposed, overlaying fabric. The thread or yarn in either of the fabrics can be broken without freeing the stitches. Hence, the vertically extending Wales are not only reinforced circumferentially of the hose by their adjoining wales but, in addition, are reinforced longitudinally of the wales and the hose by the stitches of the interknitted, superimposed, overlaying fabric.

In the present invention, each stitch in the forming and shaping fabric is substantially uniform in size. Thus, the hosiery has an appearance substantially similar to the appearance of plain knit hosiery. However, unlike plain knit hosiery, the hosiery of the instant invention will not run or ladder even though the hose is punctured with a hole of substantial size.

The hosiery of the present invention is knitted on a circular knitting machine adapted for selectively knitting plain, tucked and floated stitches in courses and wales extending circumferentially and longitudinally of the fabric, respectively. One such machine which has been found to be acceptable for knitting the instant hosiery is the Model KN machine manufactured by Scott & Williams, Inc., Laconia, New Hampshire. The basic principles of these machines are shown and described in United States Patent 1,282,958. The Model KN machine presently in wide use in the hosiery industry and on which the instant hosiery has been successfully knitted is described in the instruction manual of Scott & Williams, dated January 1955. As best shown on Plates 2l and 21-A of this manual, the machine is provided with a single knitting station, including the usual right-hand and left-hand stitch cams. A yarn feeding throat is provided above the stitch cams and regular feed fingers are provided to feed yarns to the needles at the level of the throat plate While float feed fingers are provided to feed yarns to the needles at a level above the throat plate. For purposes of knitting the instant hosiery, it is preferred to equip the knitting cylinder of such machine with needles of the type used in conventional knitting where yarn is floated into the fabric. Such needles are commonly referred to as forward hook needles.

While the invention is described herein with respect to the KN circular knitting machine, it is to be understood that other circular knitting hosiery machines which can be selectively operated to knit plain stitches, tucks and floats, may also be utilized. The particular configuration of the knitting machine is of little importance so long as the fabrics herein described can be concurrently knitted thereon.

In knitting the hosiery, both fabrics are knitted simultaneously. That is, both fabrics are formed in a single operation of the knitting needles. The needles of the knitting cylinder are divided, alternately, into two groups. For purposes of convenience in describing the preferred embodiment, the even numbered needles of the knitting cylinder will be identified as the first group, and the odd numbered needles, as the second group.

4 In the preferred embodiment, the first group of needles is set to knit While the second group of needles is set to tuck. In this embodiment, two threads or yarns are employed. The first yarn is fed into the hooks of all needles and knitted into plain stitches by the first group of needles while it is tucked by the second group of needles. The second thread is fed into the hooks of the needles of the first group and knitted into plain stitches While it is floated behind the needles of the second group. When positioned behind the needles, the second thread is not in position to contact the needle hook. The second thread is positioned to be knitted into plain stitches along with the first thread by the knitting needles and fioated when the second group of needles tuck the first thread. The first group of needles, that is, the even numbered needles, simultaneously knit plain stitches from both threads for two revolutions of the needle cylinder while the second group of needles, that is, the odd numbered needles, form tuck stitches of the first yarn and floats of the second yarn for such two revolutions. At the end of the second revolution of the needle cylinder the operation of the needles is reversed. In the following two revolutions, the first group, or even numbered needles, are set to tuck the first yarn and float the second yarn and the second group of needles, the odd numbered needles, are set to simultaneously knit plain stitches from both the first and second yarns. After two revolutions of the needle cylinder the groups are again reversed and this reversing, every two revolutions, is continued for the full length of the stocking.

Although the first yarn is positioned for control by the needle hooks throughout the knitting operation, that is, is either positioned to be knitted by the knitting needles or tucked by the tucking needles, the fabric knitted with the first yarn or thread is not the fabric which forms and shapes the hosiery. Rather, the second yarn which is knitted on only every other needle is knitted into the fabric which forms and shapes the hosiery. In the finished stocking, the knitted fabric of the first yarn is superimposed on and overlays the fabric of the second yarn.

The first and second yarns may be of any weight suitable for knitting on `a circular hosiery machine. The yarns may be relativelyfine, for example seven denier monoflament, or may be forty denier multifil-ament yarn. If desired, one yarn may 'be of one Weight or denier and the other of another weight or denier. As is obvious, however, the sheerness of the formed hosiery will, to an appreciable extent, be affected by the weight or denier of the yarn. Relatively fine thread or yarn, as would be expected, forms the more sheer fabric.

The first and second yarns are both fed to the needles of the knitting cylinder in the conventional feeding throat. The first yarn is fed to the needles at the level of the throat plate, the same position conventionally employed for knitting plain knitted hosiery. The second yarn is fed to the knitting cylinder at a level above the throat plate, the same position conventionally employed when float yarn is laid into the fabric. The yarns are fed from spools mounted in a conventional manner on the knitting machine and through conventional guides. Sufficient drag is maintained on the spools to feed the thread to the needles without kinking or distortion of the threads.

To fully understand the composite, multi-fabric hosiery of the instant invention, a review of the individual fabrics is necessary. The fabric knitted with the second yarn or thread shapes and forms the hosiery and will be reviewed first.

When considered from the standpoint of the knitting operation, each course of the forming and shaping fabric (FIGURE l) requires two complete revolutions of the needle cylinder While the needles alternately form knitted plain stitches and fioats. Since the knitting and floating operation is reversed after two revolutions of the needle cylinder, each Wale is knitted alternately of two plain stitches and two floated stitches. However, as the forming and shaping fabric forms, the plain stitches n each Wale are joined into a continuous chain of plain stitches and the floats are merged With the plain stitches to form merged courses of stitches, each merged course containing, in each Wale, a plain stitch and a float. Thus, two knitting courses or rotations of the knitting cylinder forms a single, merged course in the fabric.

Referring now to FIG. 1, the fabric pattern of the forming and shaping fabric has been diagramed for purposes of illustration. yIn the diagram, Ifive Wales and four merged courses of the fabric are illustrated. The Wales of the fabric are designated I, II, III, IV, V from left to right, respectively, and the merged courses, as they appear in the fabric, A, B, C, D commencing from the bottom of the illustration. The yarn is shown alternately With open lines and stippled lines, each open line and each stippled line designating a section of yarn or roW of loops knitted `during one knitting revolution of the knitting .cylinder. It is to be understood that this fabric is knitted from a single, continuous thread.

In the second revolution of the needle cylinder in knitting the course immediately preceding course A, the needles in Wales I, III and V Were set to tuck or float and the needles in Wales II and IV Were set to knit. As hereinabove noted, the yarn of the forming and shaping fabric is fed behind the tucking needles and is, therefore, floated. Thus, in the second revolution in the course preceding course A, knitted stitches a, b, and c Were formed in Wales I, III, and V, and in Wales II and IV floats, not shown, were formed. Stitch loops d and e had been formed on the needles in Wales II and IV during the first revolution of the needle cylinder in knitting the course immediately preceding course A when the needles in such Wales Were knitting but had been held by the needles, that is, not cast ofI, When such needles Were reversed to tuck or float. In the first rotation of the knitting cylinder in knitting course A, the operation `of the needles is as in the second revolution of the preceding course, that is, in Wales II and IV the needles knit and in Wales I, III, and V the needles tuck and float.

In Wale I, thread N is passed behind the needle and is floated, forming float k. In Wale II, thread N passe-s in front of the needle and is engaged by the needle hook, forming loop l through loop d on the needle from the prior knitting operation of such needle. Loop d is cast off the needle and formed into the fabric. In Wale III, thread N is passed behind the needle and is floated in course A behind stitch b formed in the fabric in the preceding knitting operation of that needle. Thread N is knitted and floated in Wales IV and V, respectively.

When the knitting cylinder has completed a knitting revolution, the operation of the needles is reversed, that is, the needles in the even numbered Wales are setto tuck and float and the needles in the odd numbered Wales are set to knit. `On the next revolution of the knitting cylinder, the section of yarn designated M is knitted into course A.

In Wale I, thread M is knitted into the loop of stitch a and stitch a is cast off the needle into the fabric. Loop f is formed and held by the needle. In Wale II, thread M is passed behind the needle and is floated to form float g. In Wales III and V, thread M is passed in front of the needles and is knitted into the loops of stitches h and j, respectively, as `stitches b and c are cast from the needles into the fabric. Loop lz is formed in thread M and held by the needle in Wale III and loop j is formed and held by the needle in Wale V. In Wale IV, thread M passes behind the needle to form float stitch i.

Course B of the fabric is then knitted. In the first rotation of the knitting cylinder in knitting course B, the operation of the needles is as in the previous knitting revolution of the knitting cylinder, that is, in Wales II and IV the needles are set to float and in Wales I, III, and V to knit.

Thread P is passed in front of the needle in Wale I, is engaged by the needle hook and forms loop t thorugh loop f held on the needle from the previous knitting op eration. Loop f is cast off the needle in Wale I and formed into the fabric. In Wale II thread P passes behind the needle and is floated as float u. In Wale III thread P is passed in front of the needle, is engaged by the needle hook forming loop v through loop h on the needle from the prior knitting operation. Loop h is cast off the needle into the fabric and loop v is held by the needle in Wale III. In Wales IV and V thread P is floated and knitted, respectively.

After the knitting cylinder has completed a knitting revolution, the operation of the needles is again reversed, that is, the needles in the even numbered Wales are set to knit and the needles in the odd numbered Wales are set to tuck.

Thread O is passed behind the needle in Wale I and is floated, forming float stitch r. In Wale II thread O passes in front of the needle and is engaged by the needle hook forming loop s through loop l held on the needle from the prior knitting operation of such needle. Loop l is cast off the needle and formed into the fabric. In Wale III thread O is passed behind the needle and is floated behind stitch h. In Wales IV and V thread O is knitted and floated, respectively.

Fabric courses C and D are knitted in a manner similar to courses A and B. After each tWo complete revolutions of the knitting cylinder, the knitting operation of the knitting needles is reversed, that is, fortwo revolutions the needles in Wales I, III and V knit the yarn or thread and the needles in Wales II and IV float the thread. In the following tWo knitting revolutions of the cylinder the needles in Wales I, III and V float the thread and in II and IV, knit the thread.

As can be seen from the foregoing description, the course which appears as a single course in the fabric is formed by tWo revolutions of the knitting cylinder. Each revolution knits a section of the thread into a row of alternating plain and float stitches. In the instant embodiment, the stitches are so arranged that the stitch in each Wale includes a plain stitch and a float. The plain stitches in each Wale are connected or interlooped to form a chain of plain stitches extending longitudinally of the Wale. The chain of plain stitches in one Wale is not connected to the chain of plain stitches in the Wales immediately adjoining on opposite sides but, rather is connected by floats to the plain stitches of the Wales, once removed, on either side. This feature of the forming and shaping fabric of the instant invention is considered to be of substantial importance, since it provides reinforcement transverse to the Wale at each stitch and, at the same time, sufficient elasticity to make the fabric serviceable.

The above-described forming and shaping fabric shapes and contours the stocking and establishes the knit pattern of the fabric. Knitting is in the conventional direction, that is, the top or enlarged leg portion of the hosiery is knitted first. As the knitting progresses downwardly into the lower leg and ankle portion the stitches are tightened and their size decreases to contour and shape the hosiery. This is accomplished by following customary practice.

As the forming and shaping fabric is knitted, a second fabric is simultaneously knitted. This second knitted fabric overlays the forming and shaping fabric, filling the fabric and, at the same time, combining With the forming fabric to reinforce the knitted stitches and make the hosiery run-proof.

While the thread of the overlaying and filling fabric (FIGURE 2) is fed to the front or hook side of all of the needles and is positioned on these needles for full needle control and for alternate knitting and tucking With each rotation of the needle cylinder, the size of the filling fabric is controlled and limited by the concurrent formation of the above-described forming and shaping fabric. Hence, the stitches concurrently formed in the overlaying fabric are not of the size and shape Which would be formed if the thread were knitted in such fabric in the absence of the concurrent knitting of the forming and shaping fabric.

FIG. 2 shows, diagrammatically, the stitch formation in the overlaying fabric when such fabric is knitted alone and in the absence of the concurrent knitting of the forming and shaping fabric. This fabric is knitted with the same needle arrangement as in knitting of the composite fabric of the instant invention, that is, the needles are set to alternately knit and tuck in each rotation of the needle cylinder. After two rotations of the needle cylinder, the needles are reversed for two rotations, that is, the `needles which in the preceding two rotations were knitting, now tuck for two rotations While the needles which were tucking now knit for such two rotations.

Referring to FIG. 2, the wales have been designated from left to right I', II', III', IV' and V', and the courses are each formed by two revolutions of the knitting cylinder with a single row of alternating plain stitches and tucks being formed during each rotation, as indicated from bottom to top at A' through K'. In the diagram alternating knitted sections of yarn are shown in open and stippled lines, each open line and each stippled line designating a section of yarn or row knitted during one rotation of the knitting cylinder. It is to be understood, of course, that the fabric is knitted from a single continuous thread or yarn.

In row A', the needles of wales I', III and V are set to tuck and in wales II' and IV', to knit, the same arrangement as in the preceding row. As the knitting cylinder rotates in knitting course A', thread O' engages theneedle of Wale I' and is tucked by the needle. In Wale II' thread O' forms stitch loop b' in the hook of the needle of Wale II' and loop a', from the previous row, is cast off the needle and into the fabric. In Wale III' thread O is tucked and held by the needle. In Wale IV' thread O' forms st-itch loop d in the -hook of the needle of Wale IV and loop c' from the knitting operation of the prior row, is cast off the needle into the fabric. In Wale V' thread O' is tucked.

After row A' is completed, the needles are reversed, that is, the needles in Wales I', III' and V' are set to knit and the needles of Wales II' and IV' to tuck. In Wale I' of row B' the needle engages thread P', loops the thread through the loops tucked and held on the needle during the previous tucking operation and casts such loops from the needle into the fabric. Loop e' is formed on the needle in Wale I'. In Wale II', thread P' is tucked and held .by the needle. In Wale III', 'thread P' is looped through the loops tucked and held on the needle of Wale III' during the knitting of the two preceding rows and casts these loops from the needle into tne fabric. Loop f' is formed on the needle in Wale III. In wales IV' and V' thread lP' is tucked and knitted, respectively. Thus, rows A' and `13 collectively form a single mer-ged course in the fabric.

In row C thread Q' is looped through loop e in Wale I', casting loop e' into the `fabric and forming loop g' in the wale. In Wale II thread Q is tucked and held by the needle. In Wale III threadQ' is looped through loop f', casting loop f' off the needle into the fabric and forming loop h' of thread Q'. In wales IV' and V' thread Q is tucked and knitted, respectively.

After row C has been completed, the needles are again reversed, that is, the needles in wales I', III' and V' which were previously knitting are reset to tuck and the needels in wales II' and IV which 'were tucking are reset to knit.

In row D', thread R is tucked and held by the needle in Wale I'. -In Wale II thread R' yis looped thr-ough loop b' of thread O' and Kthe sections -of threads P and Q' tucked and held by the needle during the immediately preceding knitting of rows B and C'. Loop b' with such tucked threads is cast off the needle and formed into the fabric and loop j' is formed on the needle. In Wale III' thread R is tucked by the needle. In Wales IV and V' thread CTI R' is knitted and tucked, respectively. Rows E', F', G', H', I', I' and K are knitted similar to the aforedescribed rows.`

When knitted alone and in the absence of the concurrent knitting of the forming and shaping fabric, the overlaying and filling fabric is formed in a pattern shown magnified one hundred times in the photomicrograph of FIG. 5. As can be seen from the photomicrograph, each knitting revolution of the knitting cylinder forms a row of stitches having tucked and knitted stitches in alternating Wales. Adjacent pairs of rows of stitches merge together to form merged courses of stitches in the overlaying and filling fabric, as shown in FIGURES 2 and 5. Each Wale consists in an interconnected chain of alternating lengthened and regular stitches.

FIG. 6 is a photomicrograph of a portion of the actual hosiery fabric of the instant invention produced at a magnification one hundred times the size of the original fabric or at a linear magnification of ten to one. As can be seen from an examination of this photomicrograph, the stitch pattern in the fabric, both in the horizontal course direction and in the vertical Wale direction, is of recurring stitches all substantially of the same size. Disregarding, for the moment, the loose loops and random sections of yarn, the knit pattern of the fabric is substantially identical to the pattern of the forming and shaping fabric shown, diagrammatically, in FIG. 1 and in the photomicrograph of FIG. 4. While both the forming and shaping fabric and the overlaying and filling fabric were knitted concurrently, there is no apparent resemblance in the photomicrograph of FIG. 6 to the pattern of the overlaying |fabric shown diagrammatically in FIG. 2 and photomicrographically in FIG. 5.

The overlaying and filling fabric may be knitted relatively loose into the composite hosiery fabric or may be relatively tight. However, if knitted too loose, as the thread or yarn is knitted into the overlaying and filling fabric, the thread may be released by, or become disengaged from the knitting needle before the needle knits the intended stitch. Thus, large, free loops of thread or yarn Will be formed in the fabric. While such large, free loops do not detract, in any noticeable extent, from the run-proof qualities of the composite hosiery fabric, such loops, if large enough, will project outward and detract from the appearance of the fabn'c. Even when the overlying and filling fabric is knitted relatively tight, that is, Where the knitted loops :in such fabric are not substantially larger than the stitches in the forming `and shaping fabric, the thread or yarn may occasionally become released or disengaged 'before knitting. Where this happens, however, such loops are of such size that they do not seriously affect the hosiery fabric. In either event, should a thread in the hosieryvbecome snagged While the hosiery are being worn the thread may be pulled out, broken off and thrown away without forming a run or affecting the run-proof properties of the hosiery.

While it is desirablerto knit the overlaying and filling fabric into the composite hosiery fabric relatively tight, if knitted too tight the filling fabric will distort the uniform stitch formation of the forming and shaping fabric. This results in a non-uniform stitch vformation in the composite fabric, makes the hosiery stiff and non-elastic and does not form the desired run-proof fabric.

To knit the composite fabric of the instant invention and at the same time, control the stitch formation in the overlaying and filling `fabric so that such stitches are formed in the intended knitted pattern, it has been found preferable to equip the knitting cylinder of the knitting machine with forward hook needles having enlarged hooks. One such needle which has been found suited is the #3962 needle, a standard commercial needle manufactured and sold by Textile Machine Works of Reading, Pennsylvania, and Torrington Needle Company, Torrington, Connecticut. It lhas also .been found preferable to employ, with such needle, a sinker longer than normally Q used. One such sinker is shown as #5005 in the Flat Parts catalogue, dated January 1959, of Scott and Williams, Inc., Laconia, New Hampshire.

In addition to the foregoing, considerable advantage in controlling the overlaying and filling yarn has been found by modifying the operation of the sinkers. In normal operation the needles of the knitting cylinder of a single feed circular knit machine have two positions in their circular path of travel at which they can be operated to knit. These positions are spaced in an arc of approximately In one position the needles are actuated to knit a substantial portion of the hosiery and are only actuated in the other position at the time when the knitting cylinder is knitting in a recipiracting motion to knit the heel and toe reinforcing portions. When the needles are knitting, of course, the sinkers Amust be Withdrawn. It is the usual practice in knitting hosiery to withdrawn the sinkers from between the needles as the knitting cylinder approaches the rst needle knitting position and to hold the sinkers out until the cylinder has passed the second knitting position. Thus, in usual practice, the sinkers are Withdrawn from between the needles and held Withdrawn While the needle cylinder passes through an arc slightly greater than that between the two knitting positions.

In knitting the hosiery of the instant invention it has been found advantageous to maintain the sinkers in position between the needles for a greater portion of the path through Which the needles are rotated. This is accomplished by withdrawing the sinkers only at that point in the path Where the needles actually knit. Thus, rather than Withdraw the sinkers just prior to the first knitting position of the needles and maintain the sinkers Withdrawn until the knitting cylinder passes the second knitted position, in the practice of the instant invention the Withdrawn sinkers are reinserted between the needles immediately after the cylinder passes the first knitting position. The sinkers are again Withdrawn just prior to the second knitting position and are reinserted between the needles immediately thereafter. This is accomplished by an appropriate alteration in the cam which controls the sinkers.

Referring again to the drawings, in FIG. 3 the composite fabric of the instant invention has been diagramed to illustrate the interaction between the threads or yarns in the stitches of one fabric with the stitches of the other fabric. In preparing this diagram the stitches of the overlaying and filling fabric have been shown much tighter and more regularly than they occur in the actual fabric. This can be readily seen by a comparison of the diagram of FIG. 3 With the photomicrograph of the actual fabric shown in FIG. 6. However, the stitch formation in the actual composite fabric is substantially the same as that shown in the diagram, the regularity and tightness of the diagram merely serving to better explain and illustrate such fabric.

In the diagram of FIG. 3, the thread of the forming and shaping fabric is shown stippled and the thread of the overlaying and lling fabric in open lines. This has been done for purposes of illustration :and does not, in any Way, indicate any difference in the relative Weight, denier or other properties of the respective threads. As has been noted above, the thread or yarn of both fabrics can be of the same or of dierent Weight and denier. Where threads of different denier are used, either fabric may be knitted from the heavier thread.

Both the forming and shaping fabric and the overlaying and filling fabric have each been separately described above, the former fabric having been described in wales and courses both from the standpoint of the theoretically knitted pattern and the pattern as it appears in the actual fabric. In the following description the composite fabric is discussed as it appears actually knitted. It is to be understood that each course as it appears in the fabric l@ of FIG. 6 and in the diagram of FIG. 3 is formed by two complete knitting revolutions of the knitting cylinder.

In FIG. 3, the Wales have been designated, from left to right, I, II, III" and IV", and the courses from bottom to top, A", B, C and D. In the formin-g and shaping fabric, Wales I and III" each contain a chain of interconnected plain stitches connected across Wale II by floats. Wales II and IV each contain a chain of plain stitches connected across Wale III" by floats. Although knitted from a single thread or yarn, the forming and shaping fabric is two interwoven, knitted fabrics, each formed in alternating wales by plain stitches and oats, the plain stitches of one fabric being in those Wales having the floats of the other fabric.

In addition to the plain stitches and floats of the forming and shaping fabric, each stitch in each Wale contains either a plain stitch or a combined tucked stitch of the overlaying and filling fabric. The tucked stitches of the filling fabric are alternated in courses and Wales. Thus, in each course and each Wale, every other plain stitch of the forming and shaping fabric is interknitted with a plain stitch of the overlaying and filling fabric. The intermediate plain lstitches of the forming and shaping fabric are interknitted with a tucked stitch of the filling fabric.

As shown in the diagram of FIG. 3, in Wale II" of course A the forming and shaping fab-ric contains a plain stitch 1. Superimposed on and concurrently knitted With this stitch 1 of the forming and shaping fabric, the overlaying and filling fabric contains a plain stitch 3 and a tucked stitch 4. In course B" of Wale II the forming and shaping fabric contains a plain stitch 7 and a float 2, the thread of plain stitch 7 is looped through and holds stitch 1 of the forming and shaping fabric in preceding course A". In course B" of Wale II" the overlaying and filling fabric contains a plain stitch 6 and a tucked stitch 5. The plain stitch 6 is looped through plain stitches 1 and 3 and tuck 4, Which were formed in preceding course A. In addition, the thread of plain stitch 7 in the forming and shaping fabric is looped through 'plain stitch 3 and tucked stitch 4 of the overlaying and filling fabric. Likewise, in course C" of Wale II, the stitch loops of the overlaying and filling fabric are interlooped through the stitch of the forming and shaping fabric, and Vice versa. For example, the thread of plain stitch 9 of the overlaying and filling fabric is looped through plain stitch 7 of the forming and shaping fabric, which was formed in course B".

From the foregoing description, should the thread in the stitch of either one of the fabrics be broken, the Wale and the connecting loops in such Wale would be held in their interlooped or knitted position by the stitch of the other fabric. Hence, disregarding for the moment the connection `across each stitch in the Wale formed b-y the float of the forming and shaping fabric and the reinforcement to the Wale afforded thereby, Wale stitches of each fabric vertically reinforce the Wale stitches of the other fabric. If the thread in one fabric breaks the knitted loop in the stitch of that particular fabric is broken. However, the knitted loop of such stitch of the other fabric remains intact, holding not only the connecting loops in the Wale of its oWn fabric but, also, the connecting loops of the fabric containing the broken thread.

It is possible, under more extreme conditions, that the thread in both fabrics might, at the same time, be broken. When such a condition occurs in a particular stitch, the loops in both fia-bries are broken. The connecting loops in the Wale are then no longer held by the chained formation of the stitches. Under these conditions, such Wale Would be held by the connections in the forming and shaping fabric form-ed by the floats transverse of the Wale in such fabric With the stitches of the Wales adjoining on the opposite sides. In addition, as the thread of the forming and shaping fabric and the overlaying and filling fabric are concurrently knitted, the threads o-f t-he respective fabrics are interknitted in the formation of certain of 1 l the knitted loops in such a way that the thread of one fabric interlocks the thread of the other fabric.

Referring now to FIG. 3A, there is shown in enlarged detail, the manner in which the threads of the fabrics are interknitted or interlocked. At the opposite sides of each of the tucked stitches of the overlaying and filling fabric, the interlooped stitches of the forming and shaping fabric intenlock and grip the thread of the overlaying and filling fabric. This interlocking is shown enlarged in FIG. 3A where thread section 6 of the overliaying and filling fabric passes through and between interlooped sections 1 and 7 of the thread of the forming and shaping fabric. Thus, thread 6 of the overlaying and filling fabric is gripped and held in the bite between thread sections 1 and 7 of the forming and shaping fabric. This bite has been shown somewhat open to better illustrate this feature.

While only one corner of one stitch is shown, it is to be understood that the above described interknitting of the thread of the overlaying and filling fabric in the bite of the loops of the forming and shaping fabric occurs on both sides of each stitch wher-e the tucked stitches are interknitted with the plain stitches of the forming and shaping fabric. Since such tucked stitches occur in every other stitch of each Wale and in every other stitch of each course, there is an interlocking of the threads of the courses at the opposite corners of every other stitch in the composite fabric. This interlocking or interknitting forms a key or anchor between the threads of the two fabrics. When the threads are broken, these points act as anchors, holding the ends of the broken thread and further reinforce the hosiery.

The composite fabric of the instant invention may be utilized throughout the hose or may be limited to the leg and foot portions. When limited to the leg and foot portions, the welt and heel and toe pockets may be knitted with a fabric reinforced in the conventional manner. In other Words, after the Welt is formed, the portion of the stocking knitted by circular rotation of the knitting cylinder is knitted with the fabric of the instant invention and the heel and toe portions, knitted during the reciprocating operation of the knitting cylinder, are knitted with any of the conventional reinforced fabrics.

The instant invention has been described above in conjunction With the lpreferred knitting pattern. It is to be Iunderstood that other patterns might also be employed. For example, the knitting and tucking needles might be reversed after every third revolution or the pattern may be varied by grouping the knitting and ing needles in pairs. For example, needles, such as, 1 and 2 may be set to knit While 3 and 4 tuck and float, etc. Changing the arrangement of the needles or the number of revolutions before reversing will alter the size of the stitch and the appearance of the composite fabric. So long as two or more lfabrics are knitted concurrently in which one of the fabrics has stitches substantially equal and uniform in size to form and .shape the hosiery, and the thread of the other fabric overlays and is loosely interknitted with the stitches of the forming and shaping fabric to reinforce such stitches, a run-proof hosiery of the type contemplated by the instant invention results.

The terms and expressions which have been employed are used as terms of description and not of limitation, and there isno intention, in the use of such terms and expressions, of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible Within the scope of the invention claimed.

What is claimed is:

=1. Run-proof knitted sheer ladies seamless hosiery comprising a first fabric knitted with a first yarn and a second fabric knitted with a second yarn, said first fabric having recurring in substantially parallel relationship courses and wales extending circumferentially and longitudinally, re-

spectively, of said hosiery to form and shape said hosiery, each of said Wales comprising a chain of connected, interlooped plain stitches substantially uniform in size extending longitudinally of said wales, the plain stitches in alternate wales being connected by floats extending across the plain stitches in the intermediate wales, said plain stitches and said floats of said first fabric recurring in every course thereof, said second fabric having recurring single plain stitches alternating With tucked stitches in every course and in every Wale, the plain and tucked stitches of said second fabric being joined and interknitted in plated relationship with the plain stitches of said first fabric to form loose loops and sections of yarn overlaying, intertwining and filling the plain stitches of said first fabric, said joined and interknitted stitches in said first and second fabrics interconnecting the stitches of the wales of said fabrics to hold said longitudinally extending wales and prevent said Wales from laddering when said yarns are broken.

2. Run-proof knitted sheer ladies seamless hosiery comprising a first fabric knitted With a first yarn and a second fabric knitted With a second yarn, said first fabric having recurring in substantially parallel relationship courses and Wales extending circumferentially and longitudinally, respectively, of said hosiery to form :and shape said hosiery, each of said wales comprising a chain of connected, interlooped plain stitches substantially uniform in size extending longitudinally of said wales, the plain stitches in alternate wales being connected by floats extending across the plain stitches in the intermediate Wales, said plain stitches and said floats of said first fabric recurring in every course thereof, said second fabric having recurring single plain stitches alternating with tucked stitches in every course and in every Wale, the plain and tucked stitches of said second fabric being joined and interknitted in plated relationship with the plain stitches of said first fabric to form loose loops and sections of yarn overlaying, intertWining and filling the plain stitches of said first fabric, said joined and interknitted stitches in said first and second fabrics and said floats in said first fabric interconnecting the stitches of the wales of said fabrics to hold said longitudinally extending Wales and prevent said wales from laddering when said yarns are broken.

3. Run-proof knitted sheer ladies seamless hosiery cornprising a first fabric knitted with a first yarn and a second fabric knitted With a second yarn, said first fabric having recurring in substantially parallel relationship courses and Wales extending circumferentially and longitudinally, respectively, of said hosiery to form sand shape said hosiery, `each lof `said wales comprising a chain of connected, interlooped plain stitches substantially uniform in size extending longitudinally of said Wales, the plain stitches in every other Wale being connected by floats extending across the plain stitches in the remaining Wales, and the plain stitches in said remaining Wales being connected by floats extending across the plain stitches in said every other Wale, said plain stitches and said floats of said first fabric recurring in every course thereof, said second fabric having recurring single plain stitches alternating With tucked stitches in every course and in every Wale, the plain and tucked stitches of said second fabric being joined and interknitted in plated relationship With the plain stitches of said first fabric to form loose loops and sections of yarn overlaying, intertwining and filling the plain stitches of said first fabric, said joined and interknitted stitches in said first and second fabrics interconnecting the stitches of every Wale of said fabric to hold said longitudinally extending Wales and prevent said wales from laddering when said yarns are broken.

4. Run-proof knitted sheer ladies seamless hosiery according to claim 3 wherein said first and second yarns are each monofilament nylon.

(References on following page) 13 14 References Cited bythe Examiner 3,027,737 4/ 62 Matthews et al 66-198 X Burleson X 702,843 6/02 Wilson 66-180 FOREIGN PATENTS 1,374,155 4/21 SleWe-rs 66-198 X 5 9,653 7/02 Austria 1,722,391 7/ 29 P'vfrmmer 66-196 349,728 6/31 Great Britain 2,005,093 6/35 Llebel'kneCht 66-169 455,047 10/36 Great Britain- 2,014,026 9/ 35 Nebel 66-169 2,050,462 11/36 Fleisher 65 169 DONALD W PARKER, Plmary Exammer.

2,100,861 11/ 37 Lochhead 66-169 X 10 RUSSELL C. MADER, Examiner. 

1. RUN-PROOF KNITTED SHEER LADIES'' SEAMLESS HOISERY COMPRISING A FIRST FABRIC KNITTED WITH A FIRST YARN AND A SECOND FABRIC KNITTED WITH A SECOND YARN, SAID FIRST FABRIC HAVING RECURRING IN SUBSTANTIALLY PARALLEL RELATIONSHIP COURSES AND WALES EXTENDING CIRCUMFERENTIALLY AND LONGITUDINALLY, RESPECTIVELY, OF SAID HOISERY TO FORM AND SHAPE SAID HOSIERY, EACH OF SAID WALES COMPRISING A CHAIN OF CONNECTED, INTERLOOPED PLAIN STITCHES SUBSTANTIALLY UNIFORM IN SIZE EXTENDING LONGITUDINALLY OF SAID WALES, THE PLAIN STITCHES IN ALTERNATE WALES BEING CONNECTED BY FLOATS EXTENDING ACROSS THE PLAIN STITCHES IN THE INTERMEDIATE WALES, SAID PLAIN STITCHES AND SAID FLOATS OF SAID FIRST FABRIC RECURRING IN EVERY COURSE THEREOF, SAID SECOND FABRIC HAVING RECURING SINGLE PLAIN STITCHES ALTERNATING WITH TUCKED STITCHES IN EVERY COURSE AND IN EVERY WALE, THE PLAIN AND TUCKED STITCHES OF 